Packing case with buffers for holding multi-size substrates of display device

ABSTRACT

An exemplary packing case ( 10 ) for substrates includes a main body ( 12 ), at least one buffer ( 14 ) and a cover ( 11 ). The cover is configured for attaching onto the main body. The main body includes a bottom plate ( 121 ) and a plurality of side walls ( 122 ) substantially perpendicularly extending from the bottom plate. The bottom plate and the side walls form an accommodating space. An inner surface of at least one of the side walls includes a plurality of first latching members. The at least one first buffer includes a plurality of second latching members. The second latching members and the first latching members of the at least one side wall have complementary shapes such that the at least one first buffer is detachably engagable with the at least one side wall thereby adjusting a capacity of the accommodating space.

FIELD OF THE INVENTION

The present invention relates to packing cases for containing frangible substrates, and more particularly to a packing case having buffers for holding glass substrates of display devices such as liquid crystal panels.

GENERAL BACKGROUND

The liquid crystal display (LCD) has been widely used in various electronic equipment. Glass substrates are very important components of LCDs. The two main glass substrates of a typical LCD are a color filter substrate and a thin film transistor substrate. Once the separate glass substrates have been fabricated in mass production of LCDs, the glass substrates must be properly protected during transportation to the next manufacturing stage. Therefore special packing cases with low compression deformation, high impact resistance, and high dimensional stability are needed.

FIG. 4 is an exploded, isometric view of a typical packing case for containing glass substrates of liquid crystal displays. The packing case 40 is made from polyolefin foam. The packing case 40 includes a cover 41 and a main body 42. The cover 41 and the main body 42 cooperatively form a space to accommodate glass substrates 431. The main body 42 includes a bottom plate 421, and four first side walls 422 perpendicularly extending from four side edges of the bottom plate 421. The first side walls 422 are connected end to end. Top ends of the first side walls 422 cooperatively define a peripheral first step structure 423.

The cover 41 includes a top plate 411, and four second side walls 412 perpendicularly extending from the top plate 411. The second side walls 412 are connected end to end. Bottom ends of the second side walls 412 cooperatively define a peripheral second step structure (not labeled) corresponding to the first step structure 423.

The glass substrates 431 are arranged one on top of the other, and every two adjacent glass substrates 431 are spaced by a spacing sheet 432. The glass substrates 431 and the spacing sheets 432 form a stack 43. When loading the glass substrates 431 into the packing case 40, the stack 43 is arranged on the bottom plate 421 of the main body 42, and peripheral edges of the stack 43 abut inner surfaces of the first side walls 422 and the second side walls 412. The cover 41 is attached on the main body 42. The cover 41 is fixed to the main body 42 by the fitting engagement of the first step structure 423 with the second step structure. Thus, the glass substrates 431 are loaded into the packing case 40.

However, the packing case 40 is only suitable for transporting glass substrates 431 having a certain size. Different packing cases are needed to transport glass substrates having other sizes. Thus, the cost of transporting differently sized glass substrates is correspondingly increased.

What is needed, therefore, is a packing case that can overcome the above-described deficiencies.

SUMMARY

In one preferred embodiment, a packing case for substrates includes a main body, at least one buffer and a cover. The cover is configured for attaching onto the main body. The main body includes a bottom plate and a plurality of side walls substantially perpendicularly extending from the bottom plate. The bottom plate and the side walls form an accommodating space. An inner surface of at least one of the side walls includes a plurality of first latching members. The at least one first buffer includes a plurality of second latching members. The second latching members and the first latching members of the at least one side wall have complementary shapes such that the at least one first buffer is detachably engagable with the at least one side wall thereby adjusting a capacity of the accommodating space.

Other novel features, advantages and aspects will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded, isometric view of a packing case according to a first embodiment of the present invention, also showing two glass substrates and a spacing sheet.

FIG. 2 is an assembled view of the packing case of FIG. 1.

FIG. 3 is an exploded, isometric view of a packing case according to a second embodiment of the present invention, also showing two glass substrates and a spacing sheet.

FIG. 4 is an exploded, isometric view of a conventional packing case, also showing two glass substrates and a spacing sheet.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Reference will now be made to the drawings to describe the preferred embodiments in detail.

Referring to FIG. 1, a packing case 10 according to a first embodiment of the present invention is shown. The packing case 10 includes a cover 11, a main body 12, and two buffers 14. The main body 12 and the cover 11 corperatively form a space to accommodate glass substrates 131. The buffers 14 are used to adjust a capacity of the packing case 10.

The main body 12 includes a bottom plate 121, and four first side walls 122 perpendicularly extending from four side edges of the bottom plate 121. The four first side walls 122 are connected end to end. Top ends of the first side walls 122 cooperatively define a peripheral first step structure 124.

An inner side of each of the first side walls 122 includes a plurality of first protrusions 123 extending therefrom. Each first protrusion 123 is isosceles trapezoid-shaped, and includes a first surface 1231 and two opposite second surfaces 1232. The second surfaces 1232 are equal to each other in size, and are obliquely connected to the first surface 1231. Every two adjacent first protrusions 123 define a first gap 126 therebetween. The first gap 126 is accordingly isosceles trapezoid-shaped.

Each buffer 14 has a first side surface 141, and a second side surface 142 opposite to the first side surface 141. The first surface 141 is flat. The second side surface 142 includes a plurality of second protrusions 143 extending therefrom. Each of the second protrusions 143 is isosceles trapezoid-shaped, and has substantially the same shape and size as each first gap 126 of the main body 12. Every two adjacent second protrusions 143 define a second gap 146 therebetween. The second gap 146 is accordingly isosceles trapezoid-shaped. A shape and size of each second gap 146 is substantially the same as a shape and size of each first protrusion 123 of the main body 12.

The packing case 10 is made from a foam resin having a foaming ratio of 3-30, such as an olefinic resin foam. The olefinic resin foam can be an ethylene series polymer foam such as low density polyethylene foam, high density polyethylene foam, ethylene-vinyl acetate copolymer foam, ionomer foam, olefinic polymer blend foam, polypropylene foam, and so on.

The cover 11 includes a top plate 111 and four second side walls 112 perpendicularly extending from side edges of the top plate 111. The second side walls 112 are connected end to end. Bottom ends of the second side walls 112 cooperatively define a peripheral second step structure (not labeled), corresponding to the first step structure 124 of the main body 12. The cover 11 is fixed to the main body 12 by fitting engagement of the first step structure 124 with the second step structure.

The glass substrates 131 are stacked one on top of the other. Every two adjacent glass substrates 131 are spaced by a spacing sheet 132. Thus, the glass substrates 131 and the spacing sheets 132 form a stack 130. When loading the glass substrates 131, the stack 130 is arranged on the bottom plate 121 of the main body 12. Peripheral edges of the stack 130 abut the inner sides of the first side walls 122, thus the glass substrates 131 are prevented from sliding. Then, the cover 11 is attached on the main body 12. Thus, the glass substrates 131 are loaded into the packing case 10.

Referring also to FIG. 2, when loading another set of glass substrates (not shown) having a smaller size, the glass substrates and spacing sheets (not shown) are stacked to form a new smaller stack (not shown). For example, the smaller stack may be shorter in length than the stack 130, but have the same width as the stack 130. The two buffers 14 shown are disposed in the main body 12, with the second protrusions 143 of the buffers 14 being inserted into and engaged in the first gaps 126 of the two short first side walls 122 respectively. Thereby, the first protrusions 123 of the short first side walls 122 are simultaneously inserted into and engaged in the second gaps 146 of the buffers 14. Thus, the buffers 14 are securely fixed to the main body 12, and a capacity of the main body 12 is reduced to fit the size of the smaller stack. The smaller stack is arranged on the bottom plate 121 of the main body 12. Peripheral edges of the smaller stack abut the inner sides of the two long first side walls 122 and the first surfaces 141 of the buffers 14. Thus the glass substrates are prevented from sliding. The cover 11 is attached on the main body 12. Thus, the glass substrates are loaded into the packing case 10.

In another example, the packing case 10 can include two more buffers 14. The two additional buffers 14 can be fixed to the two long first side walls 122 of the main body 12, according to the size of an even smaller stack (not shown) of glass substrates. In still another example, the packing case 10 can include a total of three buffers 14.

Unlike conventional packing cases, the packing case 10 includes the main body 12 with the first side walls 122. The inner sides of the first side walls 122 include a plurality of first latching members in the form of the first protrusions 123. The buffers 14 have a plurality of second latching members in the form of the second protrusions 143. The buffers 14 can be selectively and detachably engaged with the main body 12, by the engagement of the first latching members with the second latching members. Thus, a capacity of the packing case 10 is adjustable. Glass substrates having different sizes can be packed in the packing case 10. The peripheral edges of a stack of the glass substrates abut selected of the inner sides of the first side walls 122 of the main body 12 and/or selected of the buffers 14. Thus, the glass substrates are packed properly and tightly. No other different packing cases are needed. Therefore, the cost of transporting differently sized glass substrates is reduced.

Referring to FIG. 3, a packing case 20 according to a second embodiment of the present invention is similar to the packing case 10. However, the packing case 20 includes two first buffers 25 and two second buffers 26. The second buffers 26 are substantially the same as the buffers 14 of the packing case 10. Each second buffer 26 includes a first surface 261 and a second surface 262 at opposite sides thereof. The first surface 261 has a plurality of first gaps 266 defined thereat, and the second surface 262 is smooth.

The first buffers 25 are similar to the buffers 14 of the packing case 10. Each first buffer 25 includes a third surface 251 and a fourth surface 252. The third surface 251 has a plurality of second gaps 256 defined thereat. A shape and size of each second gap 256 is substantially the same as a shape and size of each of first protrusions 223 of a main body 22.

The fourth surface 252 has a plurality of second protrusions 253 extending therefrom. A shape and size of each second protrusion 253 is substantially the same as a shape and size of each first gap 266.

When loading glass substrates (not labeled) having a smaller size, the glass substrates and spacing sheets (not labeled) are arranged to form a stack 23. For example, the stack 23 may be shorter in length than a corresponding length of the main body 22. The first protrusions 223 of the main body 22 are received in the second gaps 256 of the two first buffers 25 shown. Thus, the first buffers 25 are fixed to the main body 22. The second protrusions 253 of the first buffers 25 are received in the first gaps 266 of the two second buffers 26 shown. Thus, the second buffers 26 are fixed to the first buffers 25. Accordingly, a capacity of the packing case 20 is reduced to fit the size of the stack 23. The stack 23 is arranged on a bottom plate (not labeled) of the main body 22. Peripheral edges of the stack 23 abut inner sides of long side walls of the main body 22 and the second surfaces 262 of the second buffers 26.

In another example, the packing case 20 can include two more first buffers 25 to further reduce the capacity thereof. The additional first buffers 25 are fixed to the long side walls of the main body 22, according to the size of an even smaller stack (not shown) of glass substrates. In still another example, the packing case 20 can include two more second buffers 26 to even further reduce the capacity thereof. The additional second buffers 26 are fixed to the two first buffers 25 at the two long side walls of the main body 22.

It is to be further understood that even though numerous characteristics and advantages of various embodiments have been set out in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

1. A packing case for substrates, the packing case comprising: a main body comprising a bottom plate, and a plurality of side walls substantially perpendicularly extending from the bottom plate, the bottom plate and the side walls cooperatively forming an accommodating space, an inner side of at least one of the side walls comprising a plurality of first latching members, at least one first buffer comprising a plurality of second latching members, the second latching members and the first latching members of the at least one side wall having complementary shapes such that the at least one first buffer is detachably engagable with the at least one side wall thereby adjusting a capacity of the accommodating space, and a cover configured for attaching onto the main body.
 2. The packing case as claimed in claim 1, wherein the at least one first buffer comprises a first surface, and the second latching members are a plurality of first protrusions extending from the first surface.
 3. The packing case as claimed in claim 2, wherein the first latching members of the at least one side wall of the main body defines a plurality of first gaps therebetween.
 4. The packing case as claimed in claim 3, wherein a shape and size of each of the first protrusions is substantially the same as a shape and size of each of the first gaps.
 5. The packing case as claimed in claim 2, wherein the first protrusions are isosceles trapezoid-shaped.
 6. The packing case as claimed in claim 5, wherein each of the first protrusions comprises two side surfaces obliquely connected with the first surface.
 7. The packing case as claimed in claim 2, wherein the at least one first buffer comprises a second surface, the first and second surfaces are at opposite sides of the at least one first buffer, at plurality of second protrusions extends from the second surface, and the second protrusions define a plurality of second gaps therebetween.
 8. The packing case as claimed in claim 7, further comprising at least one second buffer, the at least one second buffer comprising a plurality of second protrusions corresponding to the second gaps of the at least one first buffer.
 9. The packing case as claimed in claim 8, wherein shape and size of each second protrusions is substantially the same as a shape and size of each second gaps.
 10. The packing case as claimed in claim 7, wherein transverse sectional shapes of the second gaps of the at least one first buffer are identical to the first protrusions of the first surface.
 11. The packing case as claimed in claim 2, wherein the at least one side wall comprises at least two of the side walls, and the at least one first buffer comprises at least two first buffers detachably engaged with the at least two side walls, respectively.
 12. The packing case as claimed in claim 1, wherein the at least one first buffer comprises a first surface, the first surface defining a plurality of first gaps as the second latching members.
 13. The packing case as claimed in claim 12, wherein the first gaps are trapezoid-shaped.
 14. A packing case for holding substrates, the packing case comprising: a main body comprising a bottom plate, and a plurality of side walls substantially perpendicularly extending from the bottom plate, the bottom plate and the side walls cooperatively forming an accommodating space, and at least one buffer detachably engaged with at least one of the side walls of the main body thereby reducing a capacity of the accommodating space, and a cover configured for attaching onto the main body.
 15. The packing case as claimed in claim 14, wherein the at least one side wall of the main body comprises a plurality of gaps, and the at least one buffer comprises a plurality of protrusions fittingly received in the gaps thereby detachably engaging the at least one buffer with the main body. 